Reflective film and method of applying same

Abstract

A reflective film suitable for reflecting light and radio frequency energy includes a thin annealed metal foil affixed to a polymeric carrier layer or substrate wherein the polymeric carrier is thicker than the metal foil so that the foil tends to assume the physical properties, and particularly the elongation of the carrier without rupture or surface cracking of the foil upon stretching. In this manner, the polymer-metal foil laminate can be substantially deformed and stretched to fit complex shapes while maintaining a continuous, 100% reflective foil layer. The elasticity and yield strength of the substrate are selected to permit the combined foil and substrate to be stretched to fit complex shapes.

What is claimed and desired to be secured by Letters Patent of the United States is: 
     
       1. An article of manufacture for reflecting radiant energy comprising a curved support surface having cold stretch bonded thereto a partially stretched laminate comprising an extensible, continuous metal foil secured to a polymeric film, said polymer film thicker than the foil and having an ultimate elongation greater than 30% an ultimate tensile strength not greater than 21,000 p.s.i., and an ultimate yield strength not greater than 8,000 p.s.i. 
     
     
       2. The article of claim 1 wherein the metal foil comprises aluminum. 
     
     
       3. The article of claim 2 wherein the aluminum foil has a thickness of 0.00025 to 0.005 inch. 
     
     
       4. The article of claim 1 wherein the polymeric film is a polyester. 
     
     
       5. The article of claim 4 wherein the polyester has a thickness of 0.0005 to 0.002 inch. 
     
     
       6. The article of claim 1 wherein the polymeric film is a polyvinyl. 
     
     
       7. The article of claim 6 wherein the polyvinyl is selected from the group consisting of polyethylene, polypropylene and copolymers thereof, and has a thickness of 0.0015 to 0.005 inch. 
     
     
       8. The article of claim 1 wherein the polymeric film is a polyamide having a thickness of 0.002 to 0.005 inch. 
     
     
       9. The article of claim 1 wherein the polymeric film is a polyvinyl chloride having a thickness of 0.001 to 0.003 inch. 
     
     
       10. The article of claim 1 wherein the polymeric film is acrylonitrile-butadiene-styrene having a thickness of 0.0005 to 0.003 inch. 
     
     
       11. The article of claim 1 wherein the polymeric film is an acrylic having a thickness of 0.001 to 0.005 inch. 
     
     
       12. The article of claim 1 wherein the polymeric film is a polyfluorinated polymer or copolymer having a thickness of 0.0005 to 0.003 inch. 
     
     
       13. The article of claim 1 wherein the laminate is secured to the curved support surface on the foil side of the laminate. 
     
     
       14. The article of claim 1 wherein the laminate is secured to the curved surface on the polymeric film side of the laminate. 
     
     
       15. The article of claim 13 wherein the laminate is secured to the curved surface with a pressure sensitive adhesive. 
     
     
       16. The article of claim 14 wherein the laminate is secured to the curved surface with a pressure sensitive adhesive. 
     
     
       17. A laminate useful for reflecting radiant energy when secured to a curved support surface having a predetermined shape capable of substantial stretching when cold stretch applied to a curved support surface without foil rupture or delamination from the support surface comprising: an extensible continuous metal foil secured to a polymeric film, said polymeric film being thicker than the foil and having an ultimate elongation greater than 30%, an ultimate tensile strength not greater than 21,000 p.s.i., and an ultimate yield strength not greater than 8,000 p.s.i.   
     
     
       18. The laminate of claim 17 wherein the metal foil comprises aluminum. 
     
     
       19. The article of claim 14 further including a transparent film secured to the foil layer to form an outer protective surface. 
     
     
       20. A method of manufacturing a device for reflecting radiant energy comprising: securing a continuous metal foil to a polymeric film to form a reflective laminate said polymeric film being thicker than the foil and said polymeric film having an ultimate elongation greater than 30%, an ultimate tensile strength not greater than 21,000 p.s.i., and an ultimate yield strength not greater than 8,000 p.s.i.; and   cold stretch applying the laminate to a curved support surface with an intermediate pressure sensitive adhesive.   
     
     
       21. The method of claim 20 wherein the foil is secured to the polymeric film with a transparent adhesive. 
     
     
       22. The method of claim 20 wherein the laminate is cold stretch applied against the curved support surface while maintaining foil continuity by disposing the laminate adjacent the curved support surface and creating a pressure differential across the major surfaces of the laminate to form a central portion of the laminate against a central portion of the curved support surface, and increasing the pressure differential across the laminate to cause the laminate to contact the curved surface sequentially from the central portion of the curved surface toward a peripheral edge of the curved surface. 
     
     
       23. The method of claim 22 wherein the curved surface and the laminate are disposed in a vacuum chamber and wherein the laminate is disposed to form at least a partial seal against an inner surface of the vacuum chamber.